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Tesla’s 4680 cell production process outlined in Giga Berlin’s revised filings

Credit: Tesla, Tobias Lindh/Twitter

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Tesla’s revised documents for Gigafactory Berlin have been posted online, and they are a treasure trove of information. The documents provided some new details about Tesla’s planned 4680 battery plant in Gigafactory Berlin, which Elon Musk noted is on track to be one of the world’s largest battery production facilities. They also outlined how Tesla’s 4680 cells are produced. 

While sections of the filing pertaining to the planned 4680 battery cell plant in Giga Berlin were blacked out due to sensitive information that could not be made public, the documents show some important tidbits about the upcoming facility. This includes the facility’s cell production operations over four floors, with anode and cathode production on the first floor and tabless cell production on the third floor. The battery plant is massive, requiring large foundations similar to Gigafactory Berlin’s Phase 1 zone. 

Most importantly, Tesla also submitted a simplified diagram of its 4680 battery cell production process, though most of the diagram was blacked out in the revised filing’s public release. However, the company provided a brief overview of how its new battery cell will be produced in the upcoming facility (roughly translated through Google Translate). 

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“The battery the Gigafactory Berlin requires special systems and process steps. The anodes and cathodes consist of coated current collector foils. Copper is used as the material for the anode foil and aluminum is used for the cathode foil. The anode and cathode components are manufactured in mixed processes (A020-01 and A020-02), which only use materials in powder form. The new materials used are tested and approved in our own laboratory (A020-11). 

“In order for the powder coating to adhere to the two films, they must first be pre-coated with a thin layer of adhesive (substrate) (A020-03 and A020-04). This substrate is delivered in containers. The pre-coating is necessary because a dry coating with powder takes place. After the anode and cathode components have been mixed, they are applied as a coating to the respective substrate-coated film in order to establish electrical contact (A020-05 and A020-06). The current collector foils, coated with the anode or cathode components, result in the finished anode or cathode. 

The revised filings also provided a general idea of how Tesla’s tabless cell production works. Among these is the fact that the finished 4680 cells would be subjected to 10 days’ worth of curing after their formation. 

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“The anode or cathode is then cut to the required lengths with a laser in the “tabless process” (A020-08). The anode, the cathode and the separator are alternately placed one on top of the other and rolled up into a roll. This roller is then inserted into a metal housing, which is manufactured from steel rollers in a die-cutting and deep-drawing process (A020-07). In the assembly area, the final assembly and filling of the cell takes place with small amounts of electrolyte (approx. 10% of the cell weight) (A020-09). 

“The electrolyte is absorbed by the electrode coatings and enables the lithium ions to move back and forth between the anode and cathode. The housing is then closed with a lid in a welding process. The last step is the formation (A020-10) of the cell. In the formation process, the cell is electrically started up by charging and discharging it under different temperature conditions. The finished cell remains in this area for approx. 10 days and is then put to further use. The cells produced are subjected to random quality control in our own laboratory (A020-11).” 

A link to Tesla’s filings for Gigafactory Berlin could be found here

Do you have anything to share with the Teslarati Team? We’d love to hear from you, email us at tips@teslarati.com.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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xAI Colossus pollution concerns in Memphis continue

NAACP & SELC push back against xAI Colossus supercomputer. City tests say air is safe — but activists aren’t convinced.

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(Credit: xAI)

Politicians in Memphis continue to debate about the pollution concerns arising from the xAI Colossus supercomputer.

The NAACP and the Southern Environmental Law Center (SELC) have already expressed interest in filing a lawsuit against xAI over concerns related to air pollution stemming from its gas-powered turbines. Environmental groups have now raised concerns about water pollutants.

On Tuesday, Memphis released third-party air quality test results from June 13 and 16. The tests were conducted in downtown Memphis, Whitehaven, and Boxtown, two miles from xAI’s site. The city claimed levels of 10 pollutants tested were safe.

However, SELC–which is representing the NAACP in a potential lawsuit against xAI–criticized the omission of a key pollutant called ozone from the air quality tests. SELC also noted that monitors were placed against buildings, contrary to EPA guidance, stating air sensors should be “at least six feet above ground level, rooftop, or other objects and away from obstructions, vegetation, or emissions sources that would interfere with the measurement.”

Local opposition intensified, with State Representative Justin J. Pearson asserting: “I stand firm that nothing matters if you cannot breathe clean air, drink clean water, and plant in clean soil.”

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On Wednesday, concerns shifted to the Memphis aquifer, as the Tennessee Department of Environment and Conservation held a virtual meeting on xAI’s wastewater facility.

Activist Pamela Moses criticized xAI. “They are not coming here to uplift or invest in our community. They are here to exploit it. This a distressed and a historically neglected area, and instead of bringing opportunity, Colossal is bringing pollution…secrecy and broken promises,” she said.

xAI’s $80 million Grey Water facility aims to mitigate water concerns. The Colossus Water Recycle Facility, a collaboration between the Tennessee Valley Authority and Nucor Steel, aims to alleviate the strain on the aquifer.

“This project is a game changer in terms of it saving about 4.7 billion gallons of water projected, and about 4.7 billion gallons will remain in the aquifer every year,” said Bobby White of the Greater Memphis Chamber.

As xAI’s Memphis supercomputer continues to be the center of debates, the tension between economic benefits and environmental justice remains unresolved. With ongoing scrutiny and potential legal action, xAI’s efforts to address pollution and water concerns will shape its role in Memphis’ future.

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Tesla Robotaxi’s biggest challenge seems to be this one thing

That big bright thing in the sky might be Tesla’s biggest challenge in terms of Robotaxi.

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Credit: Tesla

Tesla Robotaxi launched just a few days ago to a limited number of riders in Austin, Texas, but its biggest challenge seems to be how the automaker will figure out one thing: the Sun.

Among the company’s unique strategies, its emphasis on using cameras for self-driving is perhaps the most interesting. No other company has adopted the same strategy, as others have relied on cameras with either sensors or LiDAR rigs to accomplish their self-driving deployments.

Tesla, on the other hand, has called LiDAR unnecessary. CEO Elon Musk once called it “a fool’s errand,” stating it was not needed to build an effective self-driving fleet of vehicles.

Musk compared cameras to eyes. Humans don’t need sensors or LiDAR to operate vehicles on the road, so why should cars? This brought up some questions, especially regarding sun glare. Musk said that Tesla would use direct photon counting to see directly into brigt sunlight or even in the darkest conditions at night.

His quote during a recent earnings call was:

“Actually, it does not blind the camera. We use an approach which is direct photon count. When you see a processed image, so the image that goes from the sort of photon counter — the silicon photon counter — that then goes through a digital signal processor or image signal processor, that’s normally what happens. And then the image that you see looks all washed out, because if you point the camera at the sun, the post-processing of the photon counting washes things out.”
So far, this strategy has yielded mixed results. We have seen examples of both:

The Good

We’ve had a handful of people state that they have had no issue using the Robotaxi when it is driving into direct sunlight.

There are plenty of examples:

The Bad

The Verdict

This is obviously a weird case, and it seems that this could be one of the challenges Tesla will face with the deployment of Robotaxi.

While it will get figured out, this is something that could ultimately push back Tesla’s goal of having no safety monitor in the vehicles. However, the instance will be learned and used to improve in the future through its Neural Nets.

The first intervention was captured yesterday, requiring the Tesla safety monitor to stop the vehicle manually on the car’s touchscreen.

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Tesla owners take stand as Stockholm insists on blocking FSD tests

Despite the Tesla owners’ efforts, city officials appear unwilling to budge.

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Credit: Tesla China

Tesla owners in Sweden are taking it upon themselves to lobby for the approval of FSD-style tests in the City of Stockholm. The owners’ efforts come amidst city officials’ continued refusal to allow Tesla to test its autonomous driving system in the capital.

In open letters and social media posts, Tesla owners have urged Stockholm to reconsider its stance, pointing to broader support for FSD trials across Europe. But despite their efforts, city officials appear unwilling to budge, reinforcing the capital’s hardline stance on the Elon Musk-led EV maker.

Public support shows brand loyalty

A group of Swedish Tesla owners recently sent an open letter to Stockholm leaders. Among them is Alexander Kristensen, who has written a letter to officials urging them to allow Tesla to test FSD in the region.

“Members of the Traffic Committee are politically appointed by the Stockholm City Council, whose mandate is determined by the popular vote. Your stance—continuing to block a conditional pilot of FSD— is thus a political decision and fully subject to the electorate’s judgment in the next municipal election.

“When the City prevents tests that could validate and refine the technology locally, it is perceived as hampering life-saving innovation,” the Tesla owners wrote.

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The Swedish Transport Administration issued a response, acknowledging the Tesla owners’ feedback. The Transport Administration noted that it could proceed to grant a permit for Tesla to test FSD, but the company would still have to secure approval from local governments where the FSD-style tests will be conducted.

Stockholm remains firm

Despite this, Stockholm doubled down shortly after, stating that Tesla’s FSD software remains prohibited on city roads.

“Thank you for your comments and for taking an interest in traffic issues concerning the City of Stockholm. As previously stated, the City’s assessment of the current application remains unchanged and our position is set out in the opinion,” the City of Stockhom wrote.

In light of the city’s response, some Tesla owners have vowed to campaign against current officials in the next election.

The push for FSD testing comes as Tesla faces ongoing challenges in Sweden, including a labor dispute with unions over collective bargaining agreements. Since late 2023, the conflict has resulted in strikes, blockades, and legal battles, none of which appear close to resolution. Despite regulatory and labor headwinds, Tesla continues to expand in the region, including the recent installation of Superchargers in union-backed areas.

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